Toyota is delaying the Highlander EV, but there’s a bigger problem brewing

The electric Highlander was set to go on sale soon as the current gas-powered SUV is phased out, but Toyota’s delay is creating a bigger headache.

Toyota Highlander EV delay causes a production gap

Toyota pushed back the Highlander EV launch by at least a few months. The electric three-row SUV was set to enter production at Toyota’s manufacturing plant in Georgetown, Kentucky, this month, with deliveries to dealerships by the end of 2026, but that won’t happen.

A company spokesperson confirmed the delay in July, saying Toyota needed more time to make “additional adjustments to the vehicle prior to launch,” but didn’t offer any specifics.

Toyota’s spokesperson said the company would continue building the current 2026 Highlander through December, which is available with gas and hybrid powertrains.

There’s only one issue — Toyota may run out of current models before the Highlander EV ever reaches showrooms.

Production of the Highlander EV has been delayed until at least the first quarter of 2027, and it will now launch as a 2028 model.

While the current Highlander was expected to remain available at dealerships well into 2027, Toyota’s most recent comments suggest otherwise. Toyota told Automotive News that its suppliers are “working toward a set volume,” meaning it’s unlikely to extend or increase output of the current Highlander.

For at least a few months, Highlander inventory is expected to be limited, if any remains on the lot. Whether, and by how much, the Highlander EV delay creates a gap is still up in the air.

Toyota dealers had around a 20-day supply of Highlanders nationwide as of September 10, according to Automotive News.

The bigger issue is whether or not it will impact Toyota’s sales goal. Toyota’s US sales are up 0.4% through August.

Toyota dealers are also facing limited inventory of the new RAV4 as Toyota works to ramp up production.

Not having the Highlander “will be difficult,” said Steve Gates, who owns Gates Auto Family in Kentucky, even if it’s only temporarily.

The Subaru Getaway, which will use the same underpinnings and be built alongside the Highlander EV in Kentucky, is also being delayed until at least the first quarter of 2027.

When the Toyota Highlander EV goes on sale as a 2028 model, it will be available in two trims: Limited or XLE, with front- and all-wheel-drive powertrain options.

Toyota will offer two battery packs: 77 kWh or 95.8 kWh. The former provides up to 287 miles of range, while the latter gets up to 320 miles in the FWD configuration.

Inside, the electric Highlander SUV offers three rows of seating with room for up to seven passengers. It also gets Toyota’s new Audio Multimedia System with wireless Apple CarPlay and Android Auto. The setup includes a new 12.3″ instrument cluster and 14″ central infotainment touchscreen.

The Highlander EV will join the bZ, C-HR, and bZ Woodland as the fourth electric vehicle in Toyota’s US lineup.

Electrek’s Take

While Toyota didn’t give a specific reason for the sudden delay, it’s likely to avoid another situation like the bZ4X, its first EV

Toyota issued a stop-sale and urgent recall in 2022, shortly after it went on sale, because an issue could have caused the wheels to fall off.

The updated 2026 bZ is a big improvement from the previous generation and has been among the top-selling EVs in the US since it went on sale.

While the delay may be temporary, it will give rivals like Hyundai with the IONIQ 9 and Kia with its EV9 more time to gain market share in the segment.

Once again, it appears Toyota will be late to the party.

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